A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry
Parametric investigations related to shoulder angle on tool geometry for a combined cold extrusion of a drive shaft, which consisted of spur gear and internal spline structures, were conducted through three-dimensional FE (finite element) simulations. The drive shaft was required to be about 92.00 m...
| Main Author: | |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2020-05-01
|
| Series: | Materials |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1996-1944/13/10/2244 |
| _version_ | 1797568115907756032 |
|---|---|
| author | Tae-Wan Ku |
| author_facet | Tae-Wan Ku |
| author_sort | Tae-Wan Ku |
| collection | DOAJ |
| description | Parametric investigations related to shoulder angle on tool geometry for a combined cold extrusion of a drive shaft, which consisted of spur gear and internal spline structures, were conducted through three-dimensional FE (finite element) simulations. The drive shaft was required to be about 92.00 mm for the face width of the top land on the spur gear part and roughly 22.70 mm for the groove depth of the internal spline section. AISI 1035 carbon steel material with a diameter of 50.00 mm and a length of 121.00 mm was spheroidized and annealed, then used as the initial billet material. A preform as an intermediate workpiece was adopted to avoid the excessive accumulation of plastic deformation during the combined cold extrusion. Accordingly, the cold forging process involves two extrusion operations such as a forward extrusion and a combined extrusion for the preform and the drive shaft. As the main geometric parameters influencing the dimensional quality and the deformed configuration of the final product, the two shoulder angles of <b><i>θ</i><sub>1</sub></b> and <b><i>θ</i><sub>2</sub></b> for the preform forging and the combined extrusion were both considered to be appropriate at 30°, 45°, and 60°, respectively. Using nine geometric parameter combinations, three-dimensional finite element simulations were performed, and these were used to evaluate the deformed features and the geometric compatibilities on the spur gear structure and the internal spline feature. Based on these comparative evaluations using the numerically simulated results, it is shown that the dimensional requirements of the target shape can be satisfied with the shoulder angle combination of (45°, 45°) for (<b><i>θ</i></b><b><sub>1</sub></b>, <i><b>θ</b></i><b><sub>2</sub></b>). |
| first_indexed | 2024-03-10T19:51:46Z |
| format | Article |
| id | doaj.art-a1583bd084da4ecdbb1bbea1cbf1acd2 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T19:51:46Z |
| publishDate | 2020-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-a1583bd084da4ecdbb1bbea1cbf1acd22023-11-20T00:20:14ZengMDPI AGMaterials1996-19442020-05-011310224410.3390/ma13102244A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool GeometryTae-Wan Ku0Engineering Research Center of Innovative Technology on Advanced Forming, Pusan National University, Geumjeong-gu, Busan 46241, KoreaParametric investigations related to shoulder angle on tool geometry for a combined cold extrusion of a drive shaft, which consisted of spur gear and internal spline structures, were conducted through three-dimensional FE (finite element) simulations. The drive shaft was required to be about 92.00 mm for the face width of the top land on the spur gear part and roughly 22.70 mm for the groove depth of the internal spline section. AISI 1035 carbon steel material with a diameter of 50.00 mm and a length of 121.00 mm was spheroidized and annealed, then used as the initial billet material. A preform as an intermediate workpiece was adopted to avoid the excessive accumulation of plastic deformation during the combined cold extrusion. Accordingly, the cold forging process involves two extrusion operations such as a forward extrusion and a combined extrusion for the preform and the drive shaft. As the main geometric parameters influencing the dimensional quality and the deformed configuration of the final product, the two shoulder angles of <b><i>θ</i><sub>1</sub></b> and <b><i>θ</i><sub>2</sub></b> for the preform forging and the combined extrusion were both considered to be appropriate at 30°, 45°, and 60°, respectively. Using nine geometric parameter combinations, three-dimensional finite element simulations were performed, and these were used to evaluate the deformed features and the geometric compatibilities on the spur gear structure and the internal spline feature. Based on these comparative evaluations using the numerically simulated results, it is shown that the dimensional requirements of the target shape can be satisfied with the shoulder angle combination of (45°, 45°) for (<b><i>θ</i></b><b><sub>1</sub></b>, <i><b>θ</b></i><b><sub>2</sub></b>).https://www.mdpi.com/1996-1944/13/10/2244combined cold extrusiontool geometryparametric investigationpreformspur gearinternal spline |
| spellingShingle | Tae-Wan Ku A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry Materials combined cold extrusion tool geometry parametric investigation preform spur gear internal spline |
| title | A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry |
| title_full | A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry |
| title_fullStr | A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry |
| title_full_unstemmed | A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry |
| title_short | A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry |
| title_sort | combined cold extrusion for a drive shaft a parametric study on tool geometry |
| topic | combined cold extrusion tool geometry parametric investigation preform spur gear internal spline |
| url | https://www.mdpi.com/1996-1944/13/10/2244 |
| work_keys_str_mv | AT taewanku acombinedcoldextrusionforadriveshaftaparametricstudyontoolgeometry AT taewanku combinedcoldextrusionforadriveshaftaparametricstudyontoolgeometry |